BATTERY GUARD 2000
Contents
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3. BATTERY GUARD 2000 SERVICE MANUAL PRODUCT DESCRIPTION Battery Guard 2000 is intended to be used in Fleet vehicles to prevent the battery from inadvertently being discharged by some unwanted load This may happen if a light or other accessory is left on for long periods of time Battery Guard 2000 constantly monitors the voltage level on the battery to determine the level of charge When the voltage drops below 12 0 volts for approximately 4 minutes and the ignition is off Battery Guard 2000 will automatically disconnect the battery from the vehicle s electrical system If the ignition switch is turned on the system will not disconnect the battery under any circumstances This feature prevents a shutdown in the event of a charging system failure while driving When the battery is disconnected a LED indicator on the dash mounted switch blinks to let the driver know that the system has disconnected the battery To reconnect the battery the driver needs to press the momentary switch The system now allows the driver 4 minutes to start the vehicle before the battery disconnects again If while the battery is disconnected the battery voltage goes above 13 volts as would happen during a jump start or if a charger is connected Battery Guard 2000 will automatically reconnect the battery NOTE Battery Guard 2000 is a battery charge saving device used to automatically switch off the battery in the event of a low charge condition while
4. nd the electrical system CAUTION Momentarily apply 12 Volts ONLY in both cases RESET SWITCH The RESET switch contains a LED and a momentary switch To test if the switch is faulty unplug the harness from the switch Using a small jumper wire momentarily short between the black and violet leads of the harness The Disconnect relay should click and be on Ifthe system works using the jumper the RESET switch is defective 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 2 P N 53 00660 100 Rev C 020105 BATTERY GUARD 2000 SERVICE MANUAL Trouble Shooting A System will not shut down with low 1 Check orange wire for ignition hot only battery 2 Check in line fuse 3 Check ground connection 4 Check battery voltage Battery Guard will not turn off unless battery voltage is below 12 0 volts and above 10 0 volts for more than four minutes Check for blinking LED on switch a If LED is blinking press the switch and listen for relay to click 1 If relay does not click replace module 2 If relay clicks press the test switch and hold for 3 seconds Listen for relay to click again a If relay does not click replace module b If relay clicks but power remains on in the van replace relay b If switch is not blinking replace module B System turns off prematurely Check battery voltage If battery voltage is below 12 0 volts Battery Guard 20
5. ss than 12 0 volts it momentarily applies 12 volts to Battery Disconnect relay to disconnect the power It then blinks the LED indicator on the dash mounted reset switch to indicate the disconnect 131 Eisenhower Lane North Intellitec Lombard IL 60148 630 268 0010 1 800 251 2408 www intellitec com 1 P N 53 00660 100 Rev C 020105 BATTERY GUARD 2000 SERVICE MANUAL The ignition input signal to the module is used to prevent the module from disconnecting the battery if the ignition ison This connection is very important Failure to make this connection could result in the disconnecting of the battery while driving WARNING This could lead to serious driving difficulties and a fatal accident TESTING The first step in testing Battery Guard 2000 is to locate and press the RESET switch for a minimum of 3 seconds continuously This will quickly determine if the system is working properly RESET SWITCH TEST To test the system turn off the ignition and press the RESET switch for a minimum of 3 seconds continuously The battery should be disconnected and the dash mounted indicator should be blinking momentarily Press the RESET switch to reconnect the battery Turn the ignition switch on but DO NOT start the engine LED should illuminate for 2 seconds Again press the RESET switch and hold for 3 seconds continuously The disconnect relay should not click but will remain ON The dash indicator should not be blinking If
6. the ignition is in the OFF state Power from the battery is connected directly to the disconnect solenoid without any circuit protection Inadvertent shorts of the battery cable could result in damage and or injury All Servicing of the system should be done only by a qualified technician Tools Required Low Current test light DC voltmeter HOW IT WORKS The system consists of the Intellitec Battery Disconnect relay the control module the dash mounted reset switch and the inter connect harness See Figure 1 The Battery Disconnect relay is normally mounted under the hood near the battery to keep the heavy battery cable length toa minimum The relay is a mechanically latched unit that maintains electrical connection or remains open without requiring any power from the battery To change the state of this relay 12 volts is momentarily applied to the two small I and S terminals To open the relay 12 volts is applied to the S terminal and ground to the I terminal To close the relay 12 volts is applied to the I terminal and ground to the S terminal Normally the Battery Guard controller grounds both terminals of the relay CAUTION Applying 12 volts to these terminals WILL damage the controller The control module gets its power from the inline fuse connected to the Battery Disconnect relay It monitors the voltage on the battery through this lead When it senses that the voltage on the battery is le
7. these steps work the system is working properly If they don t check the inline 5 Amp fuse and repeat the first step If this fails to make the system work further testing is required to determine the source of the failure SYSTEM TEST The next step is to determine if the module is driving the Battery Disconnect relay coil First the Ignition should be in the OFF position Connect a test light across the I and S terminals of the relay Press the RESET switch hold for 3 seconds continuously and observe the light It should blink on Press the RESET switch The light should blink on again Failure to do this indicates the module harness or RESET switch is defective The most probable cause of failure is the module If the test light blinks but the relay fails to click the relay is defective BATTERY DISCONNECT RELAY TEST Before attempting to test the Battery Disconnect relay UNPLUG the wire harness from the control module CAUTION Failure to unplug harness before applying 12 volts to these terminals WILL damage the controller o latch or turn the relay on ground the S terminal and momentarily apply 12 volts to the I terminal The rela should click and engage closing the circuit between the battery and the electrical system To unlatch or turn off the elay ground the I terminal and momentarily apply 12 volts to the S terminal The relay should click opening he circuit between the battery a
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